Integral heavy duty door knob and method of forming the same



1965 w. B. WILSON 3,200,630

INTEGRAL HEAVY DUTY DO KNOB AND METHOD SAME OF FORMING Filed NOV. 20,1962 2 Sheets-Sheet 1 1965 w. B. WILSON 3,200,630

INTEGRAL HEAVY DUTY DOOR KNOB AND METHOD OF FORMING THE SAME Filed NOV.20, 1962 '2 Sheets-Sheet 2 United States Patent 3,200,630 INTEGRAL HEAVYDUTY DOQR KNOB AND METHOD OF FORMING THE SAME William B. Wilson, LaHabra, Calif., assignor to Robert H. Miller and F. Louis Behrends, bothof Peoria, Ill. Filed Nov. 20, 1962, Ser. No. 238,973 7 Claims. (Cl.72-254) The present invention relates to the production of one-pieceheavy duty door knobs for builders locks or lock sets, and in which theknob and its integral inner tubular part are extruded of a slug ofbrass, stainless steel or other suitable metal in a high energy metalworking or extrusion press to provide a cupped member having concentrictubular parts the outer of which forms the knob and the inwardly spacedtubular part integrally formed with the end wall or face of the knob.

Although it is common practice to produce door knobs from a round blankof sheet metal by plural drawing or expanding operations resulting in aone-piece sheet metal knob having an external reduced neck portion, suchare necessarily of a relatively light weight and incapable of use wherea heavy duty knob is desired or required.

It is also common practice to reinforce such knobs formed by pluraldrawing or expanding operations with a separate insert, such as a diecasting, capable of joining the knob to the spindle of a door lock. Suchproduction not only requires plural parts but also plural operations tonest these parts together and then securely join them againstdisassembly.

Manufacturers of heavy duty knobs Vary somewhat in the methods employedin their production, but generally such heavy duty knobs consist of anouter shell, an inner shell, an inner tube and a dished washer alljoined together in rigid assembly. A typical commercial production ofsuch heavy duty knobs requires approximately five stages of draws informing the outer shell; a similar number of stages or draws arerequired to form the inner shell which is nested within andsubstantially conforms to the inner contour of the outer shell; theinner tube requires a milled slot and side operations; and the dishedwasher requires a blanking and forming stage. Next, the separate innertube, washer and inner shell are soldered and their assembly insertedinto the outer shell after which the nested inner and outer shells arerolled in and retained assembled by frictional contact.

Such prior methods of producing heavy duty knob assemblies necessarilyembody multiple parts and require multiple operations in their assembly,are expensive to produce and lack the inherent strength and rigidity ofan integral or one-piece knob unit produced in accordance with the novelmethod and manner of the present invention.

Although one-piece door knobs have been produced as pointed out abovefrom sheet metal blanks by plural drawing operations or hydraulicexpansion, so far as I am aware integral or one-piece heavy duty knobsare incapable of being produced in any similar or equivalent manner.Furthermore, only recently have metal working presses been developedwith sufiiciently high energy to be capable of extruding troma slug orbillet of brass or stainless steel for use in the production of heavy"ice carried by a depending ram and thereby providing a simple method ofcentering the preformed slug for the extrusion operation as the ramdescends and lowers the die about the upper end of the concentricpunches.

The inner or center punch if of reduced diameter adjacent its upper endto provide an annular space for flow of the extruded metal between itand the outer or encompassing punch, and this center punch islongitudinally or vertically movable relative to the outer orencompassing punch by means of an ejector a distance suflicient toinsure removal of the resulting extruded knob unit from the extrusionpress by such movement and a stripper located beneath the outer tubularpart of the cup.

Thus the present invention comprehends the manufacture of a novel cuppedextrusion unit for producing a one-piece heavy duty knob, and the novelmethod or manner of producing such a unit by extruding a slug of themetal by means of a high energy press.

While the drawings disclose the die on the upper platen, the parts maybe reversed so that the die is disposed on the lower platen in whichevent the slug or billet of metal is centered or disposed in the die, orthe die and extrusion punches may be horizontally arranged and movedhorizontally relative to each other.

The present invention further comprehends forming the inner tube forreceiving an operational tubular part of the lock assembly, oralternately forming the inner tubular part operational by providing theinner end or portion thereof with a roll back for retracting the latchbolt of the lock assembly.

Further objects are to provide a construction and method of maximumsimplicity, efficiency, economy and ease of assembly and operation, andsuch further objects, advantages and capabilities as will later morefully appear and are inherently possessed thereby.

In the drawings:

FIGURE 1 is a fragmentary view, part in vertical cross section and partin side elevation, of the separated components of a high energy pressincluding a female die and concentric extrusion punches employed in thenovel method or manner of forming a cupped member for the production ofan integral or one-piece knob and its inner tubular part, the slug ofmetal being shown centered on the outer of the concentric punches.

FIG. 2 is a view similar to FIG. 1 but showing the upper platen carryingthe die lowered to impact the metal slug and form the integral knob unitwith its concentric cylindrical parts.

FIG. 3 is a fragmentary view, part in vertical cross section and part inside elevation, showing the next step in the method of procedure inwhich the upper forrn ing die has been elevated or withdrawn from theformed knob unit on the concentric extrusion punches.

FIG. 4 is a fragmentary view, part in vertical cross section and part inside elevation, of the inner and outer concentric extrusion punches butshowing the inner punch in its raised position in the bore of the outerconcentric punch to eject or withdraw the formed outer cylindrical knobpart from the outer concentric punch.

FIG. 5 is a View similar to FIG. 4 but with the integral knob unit andits inner tubular part ejected or stripped from the inner punch.

FIG. 6 is an enlarged horizontal cross-sectional view of the completedknob and integral tube assembly formed by impact in the manner shown inFIGS. 1 to 5, inclusive, the view being taken on the line 6-6 of FIG. 7.

FIG. 7 is a view in end elevation of the integral knob and tube assemblyof FIG. 6, the view being taken from the inner end thereof.

FIG. 8 is a view in horizontal cross section taken on the line 8-8 ofFIG. 2.

FIG. 9 is a vertical cross-sectional view of an alternate integral knoband tube assembly formed by impact but with the integral inner tubeformed with a roll back to make it operationakthe View being taken onthe line 99 of FIG. 10.

FIG. 10 is a view in end elevation of the integral knob and tubeassembly of FIG. 9, the view being taken from the inner end thereof.

Referring to the disclosure in the drawings and to the novelillustrative embodiments therein shown, the present inventioncomprehends a novel heavy duty knob unit and the novel method of formingsuch unit by impacting a slug or billet of metal, such as brass orstainless steel, to form a one-piece knob unit consisting of the knob 11and its integral inner tubular part 11 projecting rearwardly through theknob from its end Wall 12. Unlike prior means and methods of producingheavy duty knobs requiring the assembly and attachment of preformedplural parts, after which the outerand inner shells are rolled togetherto maintain tight frictional engagement, the present inventioncomprehends extruding a cupped member having concentric tubular parts ina high energy press to form an integral knob and tube.

In the novel embodiment of the-present invention shown in FiGS. 1 to 8,inclusive, a preformed slug or billet'13 (FIG. 1') of the desired metal,heated or unheated, is impacted and extruded in a high energy, extrusionpress having a ram 14 provided with a downwardly opening female die 15having the contour of the intended extrusion, and upstanding concentricextrusion punches 16 and 17 with the slug of metal 1 3 centered ontheprojected end 13 of the outer punch 17, such press having suflici-entenergy to form the knob and tube integral upon impact. ,l

The inner, or center punch 16 is reduced in diameter along its upper orouter end to provide an annular space 15% between it and the innerwallof the outer or encompassing punch 17 for the flow of the extrudedmetal to aaoaeso of a tubular cam member or spindle of a lock assemblyin a door.

The outer. tubular part 26 forming the knob of the integral unit 27 isrolled in at 37 to give the finished knob the desired shape. It is to beunderstood that Where the knob is intended for use with a passage doordevoid of any locking means, the outer face or end wall 12 of the knobmay be retained devoid of .an opening, but in the event the knob isintended to receive a cylinder lock, push or turn button, this face 12is provided with a central opening conformably receiving and mountingthe cylinder, push or turn button. Or this face may be provided with anaccess opening or slotfor insertion of a key or other suitableinstrument-capable of releasing in an emergency the latching means of aprivacy lock such as used in the door of a bathroom. I

In the embodiment of FIGS. 9 and 10, the knob unit and integral tube 38therein shown is formedrby impact in the same manner as theembodiment ofFIGS. 1 to 7, inclusive, but is of slightly diiferent contour. In thisembodiment, the integral inner tubular part 3? is provided at its innerend with an arcuate projection 41 and spaced longitudinally extendingribs 42. The arcuate projection 41 with its ribs 42 forms a roll backfor actuating a latch bolt by turning of the knob.

In FIG. 9, the upper portion shows the inner end of the outercylindrical part 43jforming the knobiof the in tegral knob and tubeassembly rolled inwardlyfrom its impacted or extruded cylindrical formas shown at 44- making the knob and its inner tubular part integral inform the inner tubular part 11. This inner wall has a slight upward andoutward taper at 21 to facilitate removal of the tubular part 11. Theinner punch 16 is longitudinally movable relative to the outer punch 17by means of an ejector 22 a distance permitted by the spacing betweenthe inclined surface 23 on the enlarged end 24 of the inner punch 16 andthe complementary incline-d surface 25 of the outer or concentric punch17, sufficient to. remove the resulting outer tubular or cylindricalpart 26 of the extruded cupped member 27 from the outer concentricextrusion punch 17 (FIG. 4), after which a stripper mechanism 28 engagesthe lower-or free end 30 of the outer tubular part 26 and longitudinallymoves the cupped member 27 so formed from both extrusion punches. Thatportion of the cupped member 27 within the die has sufficient draft ortaper downwardly and outwardly to be readily released from the die whenthe latter is raised or withdrawn from the punches as in FIG. 3.

As shown in FIGS. 1 to 5 inclusive, the projected or outer end 18 of theouter or encompassing punch 17 is milled or formed with a radial slot at29 whereby to form a'stop 31 for an encompassing operational part suchas a cylinder of the lock mechanism for actuating the latch bolt. Alsoasshown in FIG. 8, the inner punch 16 is provided with a longitudinal slot32 to form a stop 33 on the inner tubular part 11, and the outerconcentric puncht17 with spaced notches 34 to form external embossments35.

The cylindrical open end of the outer and/or inner tubular part 11 and26 may be trimmed of any flash or excess material. Thereafter, theextended inner tubular part 11 is then milled to provide a longitudinalslot 3d for a key lock assembly and whatever other side operations arerequired for mounting the finished integral knob and tube assembly(FIGS. 6 and 7) to the projected end this novel manner not onlyeliminates the necessity for the plural parts previously required butalso the numerous steps in forming and uniting of plural parts asrequired in prior methods of'producing knobs capable of heavy duty use,thus effecting a substantial saving in material, time and labor.

Having thus disclosed the invention, I claim:

1. The method of forming an integral heavy duty knob assembly includinga knob and an integral internal tubular part in a high energy presswhich comprises the steps of inserting a slug of metal of lesserdiameter than that of the cavity of a female die forming the externalcontour of the knob, and impacting the outer face of the slub by meansof a ram containing the female die with the latter having an internalcontour conforming to the outer contour of the knob and concentricextrusion punches contacted by the inner face of the slug and over whichthe metal of the slug flows, the outer of said punches having a centralbore receiving a center punch having a reduced 1 free end spaced fromthe interior of the outer concentric 0 punch toprovide an annular spacetherebetween and during impact the exterior of said outer concentricpunch is encompassed by the female die with the latter spaced rem theinterior of the die to cause metal of said slug to flow into saidannular spaces to form aninternal hollow tubular part and an externalconcentric knob,with drawing the female die from the formed cuppedextruded knob assembly, withdrawing the. inner punch relative to theouter punch for. removing said assembly from the outer punch, andremoving said assembly from the of rolling the open inner end of theouter concentric knob part of the knob assembly inwardly to provide arolled inner edge, and longitudinally slotting the inner tubular part.

5. The method of forming an integral heavy duty door knob assembly froma slug of metal in a high energy press having a ram provided with afemale die and separate concentric extrusion punches including a solidcentral punch and an encompassing punch having a reduced outer end withsaid punches being spaced apart to form an annular recess therebetweenfor the flow of metal, said knob assembly consisting of an outer tubularpart having a depressed closed end and an integral cylindrical partformed integral with said closed end and projecting through the openend, comprising the steps of locating the slug of metal on the outer endof concentric punch, extruding said slug of metal by impact of saidcupped female die and between the latter and the pair of separate butconcentric extrusion punches with the inner punch having a reduced outerend spaced from the encompassing outer punch to provide an annular spacefor the flow of the extruded metal to form the inner tubular part andforming the outer tubular part between said outer concentric punch andthe female die, and stripping said knob assembly from the female die andconcentric punches.

6. The method of forming an integral heavy duty knob assembly as setforth in claim 5, including the step of rolling the free end of the knobpart inwardly to reduce its diameter.

7. The method of forming a one-piece heavy duty door knob assemblyprovided with spaced concentric tubular parts with the outer partproviding the knob formed with a depressed outer end and the inner partproviding an integral tubular projection extending inwardly from theinterior of the knob, comprising the steps of forming a cupped femaledie with the external contour of the knob part, forming concentricextrusion punches entering the female die upon impact with the innerpunch encompassed by but spaced from the interior of the outerconcentric punch and the outer concentric punch spaced from the interiorof the female die to direct the flow of the extruded metal about theouter concentric punch and within the annular space between the latterand the exterior of the inner punch, locating a slug of metal upon theprofiected end of the concentric punch, impacting said slug in a highenergy extrusion press carrying the female die, flowing the metal ofsaid slug about the concentric punch and between the latter and theinner punch to conform the metal to the internal contour of the die andthe external contour of the concentric punch and also flowing the metalinto the annular space between the said extrusion punches to form theconcentric tubular parts of the knob assembly, and in sequence removingthe formed extruded member from the concentric punch and stripping theformed extruded member from the inner punch.

References Cited by the Examiner UNITED STATES PATENTS 988,364 4/11Mathes 292-347 2,106,647 1/38 Neck 20710.5 2,571,767 10/51 Schlage292347 2,756,876 7/56 Watson 207--6.1 2,804,790 9/57 Lefere 207--6.12,848,264 8/ 5 8 Lynch 298347 2,911,815 11/59 Crepinsek 153 2,930,483 3/60 Kaul 207- 2,953,247 9/ 60 Walter et al. 207-6.l 2,966,987 l/ 61 Kaul207--6.1

CHARLES W. LANHAM, Primary Examiner.

ALBERT H. KAMPE, MICHAEL V. BRINDISI,

Examiners.

1. THE METHOD OF FORMING AN INTEGRAL HEAVY DUTY KNOB ASSEMBLY INCLUDINGA KNOB AND AN INTEGRAL INTERNAL TUBULAR PART IN A HIGH ENERGY PRESSWHICH COMPRISES THE STEPS OF INSERTING A SLUG OF METAL OF LESSERDIAMETER THAN THAT OF THE CAVITY OF A FEMALE DIE FORMING THE EXTERNALCONTOUR OF THE KNOB, AND IMPACTING THE OUTER FACE OF THE SLUB BY MEANSOF A RAM CONTAINING THE FEMALE DIE WITH THE LATTER HAVING AN INTERNALCONTOUR CONFORMING TO THE OUTER CONTOUR OF THE KNOB AND CONCENTRICEXTRUSION PUNCHES CONTACTED BY THE INNER FACE OF THE SLUG AND OVER WHICHTHE METAL OF THE SLUG FLOWS, THE OUTER OF SAID PUNCHES HAVING A CENTRALBORE RECEIVING A CENTER PUNCH HAVING A REDUCED FREE END SPACED FROM THEINTERIOR OF THE OUTER CONCENTRIC PUNCH TO PROCIDE AN ANNULAR SPACETHEREBETWEEN AND DURING IMPACT THE EXTERIOR OF SAID OUTER CONCENTRICPUNCH IS ENCOMPASSED BY THE FEMALE DIE WITH THE LATTER SPACED FROM THEINTERIOR OF THE DIE TO CAUSE METAL OF SAID SLUG TO FLOW INTO SAIDANNULAR SPACES TO FORM AN INTERNAL HOLLOW TUBULAR PART AND AN EXTERNALCONCENTRIC KNOB, WITHDRAWING THE FEMALE DIE FROM THE FORMED CUPPEDEXTRUDED KNOB ASSEMBLY, WITHDRAWING THE INNER PUNCH RELA-